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Portable Generator Familiarization & Troubleshooting Guide Section 3 • Generator Diagnostics and Adjustments 92
Portable Generator Familiarization & Troubleshooting Guide Section 4 • Generator Assemblies DISASSEMBLY PROCEDURES General Recommendations For the most part, portable generators are heavy and awkward to work on. It is for that reason that basic safety considerations must be incorporated into all handling and servicing procedures. Work Area Good lighting and an elevated work table will help you gain access to much of the mounting hardware and accessories found on most portable generator units. Certainly, larger is better but a good minimum size table top would be 20in. X 30in. If casters are applied to the legs of a work table, be sure they are secure and sturdy enough to support not only the generator but also allow for the work being done. CAUTION: Never attempt to lift a generator unit without help.Always ask for assistance and use proper lifting techniques and equipment when moving, lifting or servicing any generator. Recommended Hand Tools A minimum collection of standard mechanic’s hand tools should include: 3/8” drive socket set (SAE) 3/8” drive socket set (Metric) A 3/8” drive ratchet Short, medium and long 3/8” drive extensions A large (heavy) “soft” mallet A collection of wooden blocks A common screwdriver (medium length) A phillips screwdriver (medium length) A phillips screwdriver (short- ”stubby”) A large (heavy duty) screwdriver suitable for mild prying Medium external snap ring pliers Available Service Kits: Rotor Removal Kit Part # 41079 Electronic Measuring Equipment The measuring equipment used in troubleshooting should be of industrial quality and have the sensitivity to measure electronic values to the third decimal. Its accuracy should be within acceptable tolerances. Procedure Overview What follows is a general procedure for the disassembly and reassembly of units using the standard Generac® wound generators, as well as units using the Sincro® wound generators. The Generac® wound units may be categorized as those using brush and slip ring assemblies.The Sincro® wound units fall into the “brushless” category. This section includes the steps necessary to gain access to constituent parts such as the capacitor, stator connections, and main rotor components for both types of generator units.Although complete unit disassembly is shown, the individual electrical tests which can be performed at specific stages, are mentioned in order to help expedite the troubleshooting process. The specific models used in this discussion share general similarities that apply to most other Generac® generators. Some variations will be noted from model to model. These procedures assume that you have a suitable work area as well as the necessary tools described earlier in this section. 93
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GENERATOR

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